Catalyst preparation process

Abstract

A process for forming a catalyst from a catalytic metal precursor, a chelating bisphosphite and a bulky monophosphite, with a slightly greater than stoichiometric amount of chelating bisphosphite relative to catalytic metal under a CO partial pressure at least 25 psig.

What is claimed is: 
     
       1. A process comprising (A) forming a hydroformylation catalyst by contacting under reaction conditions, in the presence of a solvent, a catalytic metal precursor, at least one organopolyphosphite ligand, CO, hydrogen, a bulky organomonophosphite ligand and, optionally, an olefin, wherein: the molar organopolyphosphite-to-catalytic metal ratio is greater than 1 but less than 2; the partial pressure of carbon monoxide is at least 25 psig; and the molar ratio of bulky organomonophosphite-to-catalytic metal is from 5:1 to 50:1; and then (B) allowing the organopolyphosphite ligand concentration to diminish such that the ratio of organopolyphosphite ligand-to-catalytic metal falls to less than 1, wherein the contacting is conducted such that the bulky organomonophosphite is introduced at the same time or after the organopolyphosphite ligand. 
     
     
       2. The process of  claim 1  wherein the contacting is conducted such that the organopolyphosphite ligand and the catalytic metal precursor are introduced first, followed by addition of the bulky organomonophosphite. 
     
     
       3. The process of  claim 1  wherein the organopolyphosphite and the catalytic metal precursor are contacted together prior to being contacted with the bulky organomonophosphite. 
     
     
       4. The process of  claim 1  wherein the contacting is conducted such that the organopolyphosphite ligand is introduced first, followed by addition of the catalytic metal precursor, followed by addition of the bulky organomonophosphite. 
     
     
       5. The process of  claim 1  wherein the partial pressure of carbon monoxide is from 30 psig to 250 psig. 
     
     
       6. The process of  claim 1  wherein the at some point in step (A) molar organopolyphosphite-to-catalytic metal ratio is from 1.05 to 1.8. 
     
     
       7. The process of  claim 1  wherein the at some point in step (A) molar organopolyphosphite-to-catalytic metal ratio is from 1.08 to 1.2. 
     
     
       8. The process of  claim 1  wherein at some point in step (A) the amount of catalytic metal precursor is from 10 ppmw to 1,000 ppmw, calculated as free metal, based on the weight of the solvent, precursor, organopolyphosphite ligand, and organomonophosphite ligand. 
     
     
       9. The process of  claim 1  wherein at some point in step (A) the amount of catalytic metal precursor is from 25 to 500 ppmw, calculated as free metal. 
     
     
       10. The process of  claim 1  wherein at some point in step (A) the amount of catalytic metal precursor is from 50 to 350 ppmw, calculated as free metal. 
     
     
       11. The process of  claim 1  wherein the catalytic metal of the catalytic metal precursor is rhodium. 
     
     
       12. The process of  claim 1 , further comprising providing the hydroformylation catalyst to a process for hydroformylating olefins to produce aldehydes. 
     
     
       13. The process of  claim 12  wherein the partial pressure of carbon monoxide is from 30 psig to 250 psig. 
     
     
       14. The process of  claim 12  wherein the molar ratio of bulky organomonophosphite-to-catalytic metal in step (B) is maintained at from 15:1 to 50:1.